Apparatus for and method of operating on container constructions

ABSTRACT

A pair of wheels each having a plurality of die halves are rotatably driven in a synchronized manner so that each die half of one wheel is arranged opposite an associated die half of the other wheel to provide a plurality of cooperating sets of dies with each set being adapted to operate on an associated container construction. With the wheels rotating continuously, the die halves of each set are held against opposite surfaces of an associated container construction over an angular increment and during such increment a fluid under pressure is applied through one of the die halves against one of the surfaces of the construction to operate on such construction.

O Umted States Patent [151 3,673,835 Arfert 1 1 July 4, 1972 541 APPARATUS FOR AND METHOD OF 2,549,123 4/1951 Osterhof ..13 21 OPERATING ON CONTAINER 3,181,202 5/1965 Martelli et a1. ..18/21 CONSTRUCTIONS FOREIGN PATENTS OR APPLICATIONS [721 Invent Arlen 210,398 1/1967 Sweden ..83/326 [73] Assignee: Reynolds Metals Company, Richmond,

Va. Primary ExaminerRichard J. l-lerbst [22] Filed: Oct 19, 1970 Attorney-Glenn, Palmer, Lyne, Gibbs & Thompson [21] Appl. No.: 81,739 [57] ABSTRACT A pair of wheels each having a plurality of die halves are [52] US. Cl ..72/57, 72/191, 53/184, rotatably driven in a synchronized manner so that each die 425/387 half of one wheel is arranged opposite an associated die half of the other wheel to rovide a plurality of cooperating ets of [58] Field of Search ..72/57, 60, 190, 191; 18/19 RR, dies with each set being adapted to operate on an associated 18/21, 19 20 19 R; 53/184; 425/387 container construction. With the wheels rotating continuously, the die halves of each set are held against opposite sur- [56] References cued faces of an associated container construction over an angular UNITED STATES PATENTS increment and during such increment a fluid under pressure is applied through one of the die halves against one of the sur- 1,900,427 1 933 PP- R faces of the construction to operate on such construction. 3,380,272 4/1968 Halter ..72/60 Clerke ..18/21 16 Claims, 7 Drawing Figures PATENTEDJUL 4 I972 3.673835 H IS ATTORN EYS APPARATUS FOR AND METHOD OF OPERATING ON CONTAINER CONSTRUCTIONS BACKGROUND OF THE INVENTION Numerous disposable dish-like containers are used currently for packaging food products, for example, and because of the highly competitive nature of the food packaging industry it is important that these containers be made in a highspeed economical manner, using a minimum amount of material yet assuring that each container has optimum structural integrity and is capable of containing products in a fluidtight manner.

It has also been found that fluid-tight containers of high quality may be made with optimum economy by using cooperating sets of die halves which provide forming of a blank using a fluid under pressure while continuously rotating each set of die halves.

SUMMARY This invention provides an improved apparatus for and method of operating on container constructions in a highspeed economical manner using a pair of carrier wheels each having a plurality of die halves, wherein the wheels are rotatably driven in a synchronized manner so that each die half of one wheel is arranged opposite an associated die half of the other wheel to provide a plurality of cooperating sets of dies with each set being adapted to operate on an associated container construction. With the wheels rotating continuously, the die halves of each set are held against opposite surfaces of an associated container construction, such as a blank which is to be formed, for example, over an angular increment and during such increment a fluid under pressure is applied through one of the die halves of the set against one of the surfaces of the blank to form an associated container having a configuration determined by the configuration of a die cavity provided in the other die half of the set.

Other details, uses, and advantages of this invention will become apparent as the following description of the embodiments thereof presented in the accompanying drawings proceeds.

BRIEF DESCRIPTION OF THE DRAWINGS The accompanying drawings show a present exemplary embodiment of this invention, in which FIG. 1 is a perspective view with parts broken away, particularly illustrating one exemplary embodiment of the apparatus and method of this invention which uses a pair of cooperating carrier wheels each having a plurality of die halves;

FIGS. 2-6 are similar views with parts of each view in crosssection and other parts broken away illustrating the manner in which associated die halves provided on the pair of wheels cooperate at successive forming positions to form an associated flat blank; and

FIG. 7 is a view in elevation particularly illustrating electrical switches and an associated cam provided to control rotary actuators each used to position an associated die half.

DESCRIPTION OF ILLUSTRATED EMBODIMENT Reference is now made to FIG. 1 of the drawings which illustrates one exemplary embodiment of the apparatus and method of this invention which is designated generally by the reference numeral 10. The apparatus 10 comprises a pair of wheels 11 and 12 each having a plurality of die halves 13 and 14 respectively. A drive designated generally by the reference numeral 15 is provided for rotating the wheels 11 and 12in a synchronized manner so that each die half 13 of wheel 11 is arranged opposite an associated die half 14 of wheel 12 whereby a plurality of cooperating sets of dies are provided with each set being adapted to form an associated container 16.

The drive 15 comprises a drive motor 17 which is operatively connected to a gear box which has a shaft 21 extending from one end thereof and the shaft 21 is suitably operatively connected to a central supporting drive shaft 22 for the wheel 12. The shaft 22 has a driving sprocket wheel assembly 23 suitably fixed thereto and the assembly 23 is comprised of a pair of parallel sprocket wheels 24 and 25.

The wheel 1 1 also has a supporting drive shaft 26 which has a sprocket wheel '27 keyed thereto and an idler sprocket wheel 30 is rotatably supported on a shaft 31 fixed to a vertical support plate 32 comprising the apparatus 10. A chain drive 33 extends around and meshes with teeth on sprocket wheels 24 and 30 and operatively engages teeth provided on sprocket wheel 27, so that supon energizing the motor 17 to rotate shaft 21, the wheels 11 and 12 are driven in a positive, synchronized and non-slipping manner.

The apparatus 10 has a pair of vertical supports 34 arranged in parallel relation on opposite sides of the wheel 1 l and each support 34 has a horizontal slot 35 provided therein which allows rotation of the shaft 26 and wheel 11. The slots 35 also allow horizontal movements of the shaft 26 and hence the wheel 11 toward and away from the wheel 12 while still providing positive engagement of the sprocket wheel 27 with the chain drive 33 to thereby assure synchronized rotating movements of the wheels 11 and 12 during movement of the wheel 11 toward and away from the wheel 12 and for a purpose to be described in detail subsequently.

The apparatus 10 also has a pair of aligned openings extending through the support plates 32 and has a device in the form of a rotatable shaft or spindle 37 which is adapted to support supply roll 40 of sheet material for unwinding rotation. The sheet material employed in this example is in the form of metallic foil and the containers 16 made therefrom are dishlike containers.

The shaft or supporting spindle 37 extends through the aligned openings 36 whereby the supply roll 40 is supported for unwinding rotation so that the leading end portion 41 thereof extends over an idler roll 42 and vertically downwardly so that it is engaged on opposite surfaces thereof by the die halves of wheels 11 and 12 to pull and unwind sheet material from the supply roll 40 as determined by the rotation of wheels 1 1 and 12. If desired, the supply roll 40 may be provided with a suitable tensioning device, or the like, to assure controlled unwinding of sheet material therefrom.

Each of the die halves 13 and 14 of wheels 11 and 12 respectively has an associated die cavity 43 therein and in this example the die cavity 43 in each die half 14 defines the configuration of an associated container 16 and enables each container to be formed by injecting a fluid, such as air under pressure, against one surface of an associated blank 44, see FIG. 3, with such blank held between associated die halves.

The apparatus 10 also has an endless conveyor 45 which is rotatably supported by rollers 46 so that one end of the conveyor and its supporting roller is arranged beneath the wheel 12 with a shaft 47 extending from such supporting roller. The shaft 47 has a sprocket wheel 48 suitably keyed thereto and another chain drive 50 extends around the sprocket wheel 48 and the sprocket wheel 25 of the assembly 23 whereby the motor 17 is also used to drive the endless conveyor 45 and such conveyor conveys containers 16 made by cooperating forming dies of the wheels 11 and 12 away therefrom for further processing as required.

The die halves l3 and 14 have cooperating cutting edges 51 and 52 respectively which are particularly adapted to engage opposite surfaces of the sheet material unwound from the supply roll 40 to define an associated flat blank 44 having a roughly rectangular configuration, see FIG. 3. The apparatus 10 also has means for holding a cooperating pair or set of die halves against opposite surfaces or sides of an associated blank 44 through an angular increment A having sufficient length to enable fluid forming during rotation of the wheels 11 and 12.

The holding means comprises an actuator in the form of an air cylinder 55 which moves the wheel 11 toward and away from the wheel 12 in a controlled manner. The holding means also comprises a plurality of mechanisms each designated generally by the reference numeral 56 and each mechanism is associated with a die half 13 or 14 and serves to move its die half to assure a cooperating set of die halves are held against opposite surfaces of the associated blank 44 over the previously mentioned angular increment. Each mechanism 56 includes a reversible rotary actuator 60 having a driving pinion 61 fixed thereto and the pinion 61 operatively engages a toothed rack 62 which may be fixed to or provided as an integral part of an associated die half, either 13 or 14.

The apparatus has means for supplying fluid, in the form of air under pressure, which is indicatedby dotted arrows F, through one of the die halves of an associated pair during the previously mentioned angular increment. In this example, pressurized air is supplied from any suitable pressure source through a conduit 63 to the rotatable wheel 11. The wheel 11 g has a plurality of air lines 64 corresponding in number to the number of die halves 13 on wheel 11 and each line 64 exits its die half 13 through an associated orifice 65.

The wheel 11 preferably has a rotary valve means of known conventional construction provided therein which assures that air under pressure is only provided through each line 64 only during the time interval that its associated die half 13 is moving through angular increment A. Therefore, such rotary valve means have not been shown in the drawings.

Having described the major component parts of the apparatus 10, and detailed description will now proceed with particular reference being made to FIGS. 1-6 of the drawings to the highlight various positions of a cooperating set of die halves provided on the cooperating wheels 11 and 12 to air form containers 16 while continuously rotating such wheels. It will be apparent from this description and the drawing that each cooperating set of die halves operates in a substantially identical manner.

' During rotation of the wheels 1 l and 12, in the manner illustrated by the arrows 70 and 71 in FIG. 2, sheet material is unwound from the supply roll 40 by the lower portions of cooperating die halves l3 and 14 clamping sheet material therebetween as shown in FIG. 1. Continued rotation of wheels I] and 12 causes movement to the position of FIG. 2 and in this position (as in FIG. 1) the wheel 11 is in its retracted position, i.e., away from wheel 12.

Continued rotation of wheels 11 and 12 from the position of FIG. 2 results in movement of the cooperating die halves l3 and 14 to the position illustrated in FIG. 3 and during this increment of rotation the air cylinder 55 is energized as indicated by the arrow 72 to provide controlled movement of wheel 1 1. toward wheel 12 at a rate determined by the configurations and constructions of the wheels 11 and 12 and their forming dies causing the cooperating cutting edges 51 and 52 to sever an associated flat blank 44 from the sheet material. During the movement of wheel 11 toward wheel 12 the die halves l3 and 14 of the cooperating set illustrated in FIG. 3 are moved simultaneously in a precise manner relative to their associated wheels using associated rotary actuating devices or actuators 60 to thereby maintain the die halves l3 and 14 against opposite surfaces of the blank 44 through the angular increment A in a fluid-tight manner.

The wheels 11 and 12 continue to the position illustrated in FIG. 4 whereupon the fluid F in the form of air under pressure is introduced as shown at 73 through the associated line 64, which is flexible, to air form the blank 44 within the die cavity 43 of the associated die 14 and define a container 16. Air pressure is kept on any desired length, such as the time interval required for the wheels 11 and 12 to reach the position shown in FIG. 5, and during such interval each rotary actuator 60 continues to move its die half relative to its associated wheel while the air cylinder 55 continues to advance wheel 11 toward wheel 12 so that the cooperating die halves 13 and 14 remain in parallel relation and in contact against opposite surfaces of the blank 44 through the entire angular increment A.

After movement of the cooperating die halves through the angular increment A, the air cylinder 55 is retracted as illustrated by the arrow 74 in FIG. 6 and the reversible rotary actuators 60 are automatically reversed causing each die half to start movement so that by the time the cooperating set of die halves l3 and 14 which have just formed an associated container 16 are rotated by their wheels to the positions illustrated in FIG. 2 the actuators 60 will have returned the die halves to the positions illustrated in FIG. 2 of the drawings.

Any suitable means may be provided to control the action of the air cylinder 55 and, hence, the movement of the wheel 11 toward and away from the wheel 12 and such control means is synchronized with the rotary actuators 60 using any technique known in the art. Further, each rotary actuator 60 is controlled in a synchronized manner with the air cylinder 55 so that it moves its associated forming die in one direction or another, depending upon whether the wheels 1] and 12 are progressing from the positions indicated between FIGS. 2 and 6 or through the larger angular increment representative of the angular movement between FIGS. 6 and 2 to commence another forming cycle.

In this example of the invention each wheel 1 1 and 12 has a ring 75 suitably fixed thereto .which is provided with a plurality of electrical switches 76 each operatively connected to an associated reversible electrical rotary actuator 60. Each switch 76 has a telescoping plunger 77 which is provided with a cam roller 78 at the end thereof. The apparatus 10 also has a pair of fixed cams 80 each provided with a cam surface 81 and each cam operatively associates with a wheel 1 1 or 12.

The cam surface 81 of each cam 80 has a cam section 82 which is engaged by the cam roller 78 of each switch 76 as its forming die is moved into forming position whereupon the associated rotary electric actuator 60 is energized and moves its die half at a constant speed relative to its wheel with constant rotation of the wheels 11 and 12 until the associated forming die reaches the position of FIG. 6. In the position of FIG. 6, the cam roller 78 engages the rise 83 in the cam surface 81 which trips the associated electrical switch 76 causing reversal of the electrical actuator 60 so that as the associated wheel moves from the position of FIG. 6 to the position of FIG. 2 as previously mentioned the associated forming die is returned to its original position, of FIG. 2, in preparation for another forming cycle in the manner previously explained. If desired, suitable stops may be provided on each wheel for stopping the movement of each die half once it reaches the extremes of travel at opposite ends and each rotary actuator may be provided with overriding clutch devices to prevent damage thereto once its die half strikes a stop.

In this example of the invention the air forming of containers using blanks 44 sheared by cooperating die halves from an associated sheet of material uses air under pressure to provide the forming action. However, it will be appreciated that any suitable fluid may be utilized. Also, the angular increment during which air forming takes place may be either more or less than the roughly 45 angle illustrated and depends on the number of forming die halves provided on each wheel and the mechanical arrangement of such die halves.

In this example of the invention, the sheet material defining supply roll 40 has been described as being metallic foil. However, it will be appreciated that the apparatus and method of this invention may be used to form containers similar to container 16 using other materials including non-metallic materials.

The sources of power for the various actuators, motors, etc., have not been illustrated in this disclosure of the invention; however, it will be appreciated that suitable power sources and controls therefor are provided using conventional techniques. I

The apparatus 10 may be suitably modified to also enable embossing of container walls, heat sealing or otherwise attaching lids over open-ended containers and similar operations; therefore, it is to be understood that the term operating on used in certain of the claims presented herein is intended to cover operating on a workpiece or container construction to form, shape, emboss, seal, and other similar operations.

While present exemplary embodiments of this invention, and methods of practicing the same, have been illustrated and described, it will be recognized that this invention may be otherwise variously embodied and practiced within the scope of the following claims.

What is claimed is:

1. An apparatus for operating on container constructions comprising, a pair of substantially circular wheels each rotatable about a central axis of rotation and having a plurality of die halves, a drive for rotating said wheels in a synchronized manner so that each die half of one wheel is arranged opposite an associated die half of the other wheel to provide a plurality of cooperating sets of die halves with each set being adapted to operate on an associated container construction, means holding the die halves of each set in fluid-tight engagement against opposite surfaces of an associated container construction over an angular increment during rotation of said wheels and moving the die halves of each set in a substantially rectilinear path during said angular increment to assure said die halves remain in said fluid-tight engagement, and means supplying a fluid under pressure through one of said die halves during said angular increment to operate on the associated container construction using said fluid as the operating medi- 2. \l'l apparatus as set forth in claim 1 and further comprising a support supporting each of said wheels for rotation in a substantially vertical plane and said drive rotates said wheels in opposite directions.

3. An apparatus as set forth in claim 2 in which said drive comprises a mechanical drive and said means supplying a fluid comprises means supplying air under regulated pressure.

4. An apparatus for forming containers comprising, a pair of substantially circular wheels each rotatable about a central axis of rotation and having a plurality of die halves, a drive for rotating said wheels in a synchronized manner so that each die half of one wheel is arranged opposite an associated die half of the other wheel to provide a plurality of cooperating sets of die halves with each set being adapted to form an associated container therein, means holding the die halves of each set in fluid-tight engagement against opposite surfaces of an as sociated blank over an angular increment during rotation of said wheels and moving the die halves of each set in a substantially rectilinear path during said angular increment to assure said die halves remain in said fluid-tight engagement, and means supplying a fluid under pressure through one of said die halves and against one of said surfaces during said angular increment to define an associated container from said blank.

5. An apparatus as set forth in claim 4 in which each of the die halves on at least one of said wheels has a die cavity therein which defines the configuration of an associated container.

6. An apparatus as set forth in claim 4 and further comprising a device adapted to support a supply roll of sheet material for unwinding rotation to enable movement of said sheet material between said wheels and cooperating cutting edges on the die halves of each set for cutting said sheet material during the initial part of said angular increment to define an associated blank.

7. An apparatus as set forth in claim 4 and further comprising a conveyor for moving containers made by said apparatus away from said pair of wheels.

8. An apparatus as set forth in claim 4 in which said holding and moving means comprises an actuator for moving one of the wheels and its die halves toward the other wheel and a plurality of mechanisms each moving an associated die half.

9. An apparatus as set forth in claim 8 in which each die half has a toothed rack provided thereon and each mechanism comprises a reversible rotary actuating device having a driving pinion fixed thereto which operatively engages said rack to provide movement of the associated die half against said blank.

10. An apparatus as set forth in claim 4 in which said supplying means comprises a passage extending through one of the die halves of each set and said fluid comprises air under regulated pressure.

11. An apparatus as set forth in claim 9 in which said actuator comprises an air cylinder and said rotary actuating device comprises an electric motor.

12. A method of operating on container constructions comprising the steps of, rotating a pair of substantially circular wheels each having a plurality of die halves in a synchronized manner so that each die half of one wheel is arranged opposite an associated die half of the other wheel to define a plurality of cooperating sets of die halves with the die halves of each set being adapted to operate on an associated container construction, providing a container construction between each cooperating set, holding the die halves of each set firmly in fluid-tight engagement against opposite surfaces of its associated container construction over an angular increment during rotation of said wheels and moving the die halves of each set in a substantially rectilinear path during said angular increment to assure said die halves remain in said fluid-tight engagement, and supplying fluid under pressure through one of the die halves of each set during said angular increment to thereby operate on the associated container construction.

13. A method as set forth in claim 12in which said providing step comprises providing said container construction in the form of a blank between each cooperating set and upon supplying said fluid during said supplying step said blank is formed within a die cavity in a die half of the cooperating set to define a dish-like container.

14. A method as set forth in claim 13 in which said providing step comprises providing a flat sheet-like blank of metallic foil and said supplying step comprises supplying air under regulated pressure.

15. A method as set forth in claim 12 and comprising the further step of placing a web of sheet material between said rotating wheels and said holding and moving step comprises severing said web using the die halves of each set to define said container construction.

16. A method as set forth in claim 12 in which said rotating step comprises continuously rotating said wheels. 

1. An apparatus for operating on container constructions comprising, a pair of substantially circular wheels each rotatable about a central axis of rotation and having a plurality of die halves, a drive for rotating said wheels in a synchronized manner so that each die half of one wheel is arranged opposite an associated die half of the other wheel to provide a plurality of cooperating sets of die halves with each set being adapted to operate on an associated container construction, means holding the die halves of each set in fluid-tight engagement against opposite surfaces of an associated container construction over an angular increment during rotation of said wheels and moving the die halves of each set in a substantially rectilinear path during said angular increment to assure said die halves remain in said fluid-tight engagement, and means supplying a fluid under pressure through one of said die halves during said angular increment to operate on the associated container construction using said fluid as the operating medium.
 2. An apparatus as set forth in claim 1 and further comprising a support supporting each of said wheels for rotation in a substantially vertical plane and said drive rotates said wheels in opposite directions.
 3. An apparatus as set forth in claim 2 in which said drive comprises a mechanical drive and said means supplying a fluid comprises means supplying air under regulated pressure.
 4. An apparatus for forming containers comprising, a pair of substantially circular wheels each rotatable about a central axis of rotation and having a plurality of die halves, a drive for rotating said wheels in a synchronized manner so that each die half of one wheel is arranged opposite an associated die half of the other wheel to provide a plurality of cooperating sets of die halves with each set being adapted to form an associated container therein, means holding the die halves of each set in fluid-tight engagement against opposite surfaces of an associated blank over an angular increment during rotation of said wheels and moving the die halves of each set in a substantially rectilinear path during said angular increment to assure said die halves remain in said fluid-tight engagement, and means supplying a fluid under pressure through one of said die halves and against one of said surfaces during said angular increment to define an associated container from said blank.
 5. An apparatus as set forth in claim 4 in which each of the die halves on at least one of said wheels has a die cavity therein which defines the configuration of an associated container.
 6. An apparatus as set forth in claim 4 and further comprising a device adapted to support a supply roll of sheet material for unwinding rotation to enable movement of said sheet material between said wheels and cooperating cutting edges on the die halves of each set for cutting said sheet material during the initial part of said angular increment to define an associated blank.
 7. An apparatus as set forth in claim 4 and further comprising a conveyor for moving containers made by said apparatus away from said pair of wheels.
 8. An apparatus as set forth in claim 4 in which said holding and moving means comprises an actuator for moving one of the wheels and its die halves toward the other wheel and a plurality of mechanisms each moving an associated die half.
 9. An apparatus as set forth in claim 8 in which each die half has a toothed rack provided thereon and each mechanism comprises a reversible rotary actuating device having a driving pinion fixed thereto which operatively engages said rack to provide movement of the associated die half against said blank.
 10. An apparatus as set forth in claim 4 in which said supplying means comprises a passage extending through one of the die halves of each set and said fluid comprises air under regulated pressure.
 11. An apparatus as set forth in claim 9 in which said actuator comprises an air cylinder and said rotary actuating device comprises an electric motor.
 12. A method of operating on container constructions comprising the steps of, rotating a pair of substantially circular wheels each having a plurality of die halves in a synchronized manner so that each die half of one wheel is arranged opposite an associated die half of the other wheel to define a plurality of cooperating sets of die halves with the die halves of each set being adapted to operate on an associated container construction, providing a container construction between each cooperating set, holding the die halves of each set firmly in fluid-tight engagement against opposite surfaces of its associated container construction over an angular increment during rotation of said wheels and moving the die halves of each set in a substantially rectilinear path during said angular increment to assure said die halves remain in said fluid-tight engagement, and supplying fluid under pressure through one of the die halves of each set during said angular increment to thereby operate on the associated container construction.
 13. A method as set forth in claim 12 in which said providing step comprises providing said container construction in the form of a blank between each cooperating set and upon supplying said fluid during said supplying step said blank is formed within a die cavity in a die half of the cooperating set to define a dish-like container.
 14. A method as set forth in claim 13 in which said providing step comprises providing a flat sheet-like blank of metallic foil and said supplying step comprises supplying air under regulated pressure.
 15. A method as set forth in claim 12 and comprising the further step of placing a web of sheet material between said rotating wheels and said holding and moving step comprises severing said web using the die halves of each set to define said container construction.
 16. A method as set forth in claim 12 in which said rotating step comprises continuously rotating said wheels. 